GB2466392A

GB2466392A - Latent heat storage materials

Info

Publication number: GB2466392A
Application number: GB1001541A
Authority: GB
Inventors: Michael Trevor Berry; Janet Susan Scanlon
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-10-15
Filing date: 2009-10-15
Publication date: 2010-06-23
Anticipated expiration: 2029-10-15
Also published as: US20110089387A1; GB2462740A; GB201008025D0; GB201006119D0; GB201003004D0; GB2474534A; GB2466391A; GB2467886B; GB0918061D0; GB2468231A; GB2465870B; GB2468231B; GB2465870A; GB201010853D0; GB2467886A; GB0919406D0; GB201001541D0; US20110089386A1; GB201002873D0; GB201006127D0

Abstract

Latent heat storage materials having enhanced fire-retardant properties comprise compositions of a binder and a phase change material, in which the binder comprises dry inert powder, phosphogypsum, and an alkaline salt of any metal. The dry inert powder may be fly-ash. The latent heat storage material may additionally comprise fillers and/or intumescent agents. Processes for making these compositions are disclosed.

Description

Phase change materials with improved fire-retardant properties

Field of Invention

This invention relates to thermal energy storage compositions that incorporate organic phase change materials and have improved fire retardant properties. The compositions can be incorporated into a variety of articles including for instance foams, heating and cooling devices, and building materials.

Background of the Invention

Phase change materials and compositions are well known: these are materials which reversibly undergo a change of state and act as a sink for thermal energy, absorbing or releasing heat as necessary. For example, they can be used to reguiate temperatures within a desired range, or provide a degree of protection against extremes of heat or cold.

Paraffin wax and similar organic compounds have been used as phase change materials for building applications (such as in wallboards, sheetrock, drywall, plasterboard, and fibreboard for absorbing or releasing heat energy into or from a room environment) . However, these materials are flammable: this is particularly true for phase change materials comprising various readily combustible paraffins. This is a major drawback since it increases the combustibility of the articles.

There have been a wide variety of attempts to make the miorocapsules more flame-resistant. U.S. Pat. No. 5,435,376 describes microencapsulated latent-heat storage materials which are not combustible. However, non-combustible latent-heat storage materials of this type generally store an insufficient amount of heat. The specification furthermore discloses mixtures of latent-heat storage materials and flame inhibitors as capsule core for textiles, shoes, boots and building insulation. This admixture of flame retardants only results in a slight improvement in the combustion values, or none at all.

U.S. Patent Appl. Pub. No. 2003/0211796A1 discloses an approach that involves coating articles containing microencapsulated organic latent-heat storage materials with a flame-inhibiting finish comprising intumescent coating materials of the type used as flame-inhibiting finishes for steel constructions, ceilings, walls, wood and cables. Their mode of action is based on the formation of an expanded, insulating layer of low-flammability material which forms under the action of heat and which protects the substrate against ingress of oxygen and/or overheating and thus prevents or delays the burning of combustible substrates. Conventional systems consist of a film-forming binder, a char former, a blowing agent and an acid former as essential components. Char formers are compounds which decompose to form carbon (carbonization) after reaction with the acid liberated by the acid former. Such compounds are, for example, carbohydrates, such as mono-, di-and tri-pentaerythritol, polycondensates of pentaerythritol, sugars, starch and starch derivatives. Acid formers are compounds having a high phosphorus content which liberate phosphoric acid at elevated temperature. Such compounds are, for example, ammonium polyphosphates, urea phosphate and diammonium phosphate. Preference is given to polyphosphates since they have a greater content of active phosphorus. Blowing agents, the foam-forming substances, liberate non-combustible gas on decomposition. Blowing agents are, for example, chlorinated paraffins or nitrogen-containing compounds, such as urea, dicyanamide, guanidine or crystalline melamine. It is advantageous to use blowing agents having different decomposition temperatures in order to extend the duration of gas liberation and thus to increase the foam height. Also suitable are components whose mode of action is not restricted to a single function, such as melamine polyphosphate, which acts both as acid former and as blowing agent. Further examples are described in GB2007689A, EP1394O1A, and U.S. Patent. No. 3,969,291.

Magnesia cement-based products are known to have good fire-resistance, for example, European Patent Application Number EP2060389A1 describes a laminate panel for flooring, wall or ceiling systems having a fire-proof core layer disposed between an upper surface layer and a lower backing layer. The core layer comprises a composition derived from a colloidal mixture of magnesium oxide, magnesium chloride and water.

A publication by Dr Mark A. Shand entitled "Magnesia Cements", referred to in W02009/059908, details the three main types of magnesia cements, one of which is the Magnesium Oxychloride cement, otherwise known a Sorel cement. Shand suggests that superior mechanical properties are obtained from the "5-form" whose formula is given as 5Mg(OH)2.MgC12.8H20. According to Shand, this is formed using magnesium oxide, magnesium chloride and water in a molar ratio of 5:1:13.

W02008/063904 discloses an approach for making the five-phase magnesium oxychloride cement composition (5Mg(OH)2.MgC12.8H20) by mixing a magnesium chloride brine solution with a magnesium oxide composition in a selected stoichiometric ratio of magnesium chloride, magnesium oxide, and water. The cement kinetics are controlled to form the five-phase magnesium oxychloride cement composition and results in an improved and stable cement composition.

The key element would appear to be the utilisation of a magnesium chloride brine solution having a specific gravity in the range from about 28° Baumé to about 34° Baumé, most preferably at least about 30° Baumé. After 24h, at least 98% of the five-phase compound is present, which minimises the amount of poorly water-resistant three-phase compound. Various fillers can be optionally added to give fire-proofing compositions.

Use of magnesia cement and related components is disclosed in W02009/059908, which is concerned with the fire retardation properties of compositions including those comprising phase change material and magnesia cement. A high concentration of the 5-form is said to be preferable in inventive compositions comprising Sorel cement where superior mechanical properties are needed. The process for making these materials involves adding the phase change material to the magnesium chloride brine solution before the formation of the magnesium oxychloride cement is initiated by adding the magnesium oxide powder. These magnesia cements containing the phase change material (Examples 1 and 10-13) have molar ratios of magnesium oxide:magnesium chloride:water in the range of between about 5:1:12 (Examples 1, 10 and 11) to 8:1:16 (Examples 12 and 13).

GB2344341A discloses a forming mixture comprising a dry, inert powder, such as fly ash, pulverised rock or recycled building waste, phosphogypsum and an alkaline salt. Additives such as cellulose derivatives, pva resin, microfibres, starch ethers, water repelling agents, colour or flame-retardants, nay be included. An aerating agent e.g. a carbonate may be added to yield thermally insulating materials. The addition of a phase change material is not contemplated.

U.S. Pat. Nos. 6,099,894, 6,171,647 and 6,270,836 describe a magnesium oxide gel and other metal oxide gels as a coating for microencapsulated phase change, which result in improved flame protection of the capsules.

Disclosure of Invention

From the foregoing, it may be appreciated that a need has arisen for products that allow for a reduction in the consumption of energy derived from fossil fuels, and which can be manufactured in a way that has a low impact on the environment. Phase change materials work by absorbing heat from a room where the temperature exceeds a comfortable working environment. The heat is stored as latent heat and thermal mass, and released as the temperature of the building falls. This is a continuous cycle involving no mechanical intervention.

The present invention is a latent heat storage material comprising a binder and a phase change material, in which the binder comprises dry inert powder, phosphogypsum, and an alkaline salt of any metal.

In further embodiments, the latent heat storage material additionally comprises fillers, and/or intumescent agents.

The present invention further comprises a process for making a latent heat storage material comprising a secondary binder and a phase change material involving the steps: (a) mixing said secondary binder and water for 5 -10 minutes at h�gh speed; (b) adding phase change material and continuing to mix for a further 10 -15 minutes and (c) baking the mixture. In further embodiments, the process involves additional steps to include fillers, and/or intumescent agents.

In preterred embodiments, the phase change material is a microencapsulated formulation.

The composition can be used as a binder in aluminium, copper or graphite building elements, such as ceiling tiles, chilled ceiling systems, heating and cooling exchange units, decorative wall panels, computer room floor panels, raised access floor panels, curtain wall sections, suspended ceiling pipes and units, extrusions for lightweight concrete floors and window and door frames.

The composit�on may also comprise quartz, perlite or graphite and used to cast floor tiles, wall tiles, lightweight foamed concrete for floor screeds, work tops, panel sections, building blocks, furniture, architectural mouldings for interior and exterior applications, isolated telecommunication rooms or housing units, doors, skirtings, architraves, sleeving for heating and ventilation pipe work or ducting, and construction boards (aluminium or copper mesh to be added to the casting)

Best Mode for Carrying Out the Invent ion

Embodiments of the latent heat storage compositions of the present invention and their technical advantages may be better understood by referring to the

following disclosure.

In a first step magnesium chloride is dissolved in water of reasonable purity (such as tap water) by mixing for a minimum of 15 minutes at high speed and then left for a minimum of 24 hours to ensure that the magnesium chloride is completely d�ssolved. The dissolution step is performed under ambient conditions, typically 10 -13°C for the tap water and 15 -18°C for the resulting solution. Magnesium chloride hexahydrate preparations are commercially available and suitable for use in the present invention. For example NEDMAG(RTM) C flakes, which are small white flakes of magnesium chloride hexahydrate (MgCl2.6H20) with a MgC12 content of 47%, are available from Nedmag Industries Mining & Manufacturing 8.7. The Baumé is measured in order to be able to determine the quantity of magnesium oxide to be added in the next step (see below) The proportion of magnesium oxide in the binder affects its density and to some extent determines the quantity of the phase change mater�al and thus the enthalpy measure of the finished binder. The Baumé measures the density of a liquid, which can be either heavier or lighter than water. In the case of the present invention, the liquid density is heavier than water. Typically the weight ratio of magnesium chloride water is about 1:1, which gives a Baumé reading of 26°; this corresponds to a molar ratio of magnesium chloride: water of about 1:17. The preferred Baumé range is between 23° and 26°.

In a second step magnesium oxide is added to the magnesium chloride solution prepared in the first step and stirred for a minimum of 10 minutes with a high speed paddle drill. Magnesium oxide preparations are commercially available and suitable for use in the present invention. For example, Baymag magnesium oxide is available from Baymag Inc. and comprises 94-98% (wt/wt) of magnesium oxide and 1.5 -4% (wt/wt) of calcium oxide.

In a third step the phase change material (pcm) is added directly after the MgO: MgC1 solution has been stirred for at least 15 minutes, and is mixed vigorously. This differs from the process disclosed in W02009/059908 in which the pcm is added to the magnesium chloride solution. Preferred pcm's are organic, water insoluble materials that undergo solid-liquid/liquid-solid phase changes at temperatures in the range of 0° to 80°C. Candidate materials include substantially water insoluble fatty alcohols, glycols, ethers, fatty acids, amides, fatty acid esters, linear hydrocarbons, branched hydrocarbons, cyclic hydrocarbons, halogenated hydrocarbons and mixtures of these materials. Alkanes (often referred to as paraffins), esters and alcohols are particularly preferred. Alkanes are preferably substantially n-alkanes that are most often commercially available as mixtures of substances of different chain lengths, with the major component, which can be determined by gas chromatography, between C15 and C50, usually between C12 and C32. Examples of the major component of an alkane organic phase change materials include n- octacosane, n-docosane, n-eicosane, n-octadecane, n-heptadecane, n-hexadecane, n-pentadecane and n-tetradecane. It is also possible to include a halogenated hydrocarbon along with the main organic phase change material to provide additional fire protection, for example as disclosed in U.S. Pat. No. 5,435,376. Suitable ester organic phase change materials comprise of one or more C3 -C30 alkyl esters of C30 -C24 fatty acids, particularly methyl esters where the major component is methyl behenate, methyl arachidate, methyl stearate, methyl palmitate, methyl myristate or methyl laurate.

Alcohol organic phase change materials include one or more alcohols where the major component is, for example, n-decanol, n-dodecanol, n-tetradecanol, n-hexadecanol, and n-octadecanol. These materials are substantially water insoluble, which means they can be formulated in an emulsion form or encapsulated form.

Including a phase change material in the binder mix decreases its fire resistant properties and also alters the physical characteristics of the binder when cured. It is therefcre desirabie that the enthaipy cf phase change is high (typicaiiy >50 kJ/kg, preferabiy >100 kJ/kg and mcst preferabiy >150 kJ/kg) sc that smaiier quantities cf pcm can be used in the binder. Preferabiy, the phase change nateriai is a ccmmerciaiiy avaiiabie encapsuiated fcrmuiation, such as Micrcnai�, which has an enthaipy cf llOkJ/kg cr Encapsuiance, which has a higher enthaipy, in the range cf 150 -l6OkJ/kg. These materiais are prcvided in granuiar fcrm and may be added tc the magnesia cement binder straight nut cf the ccntainer. Using a weight ratic cf magnesia cement materials: pcm in the range cf 1:2 tc 1:3 gives a binder prcduct having an enthalpy measure cf abcut 50 kJ/kg. The quantity cf pcm used is chcsen sc that the enthalpy measure cf the binder is at cr below 5OkJ/kg. This typically ccrrespcnds tc a minimum Eurcpean fire rating cf Eurcclass U, which is described as having an "Acceptable ccntributicn tc fire" (the class system is rated on a scale cf Al, A2, B, C, U, F and F, where Al has no contribution to fire and where F has no performance requirements) In a fourth step the mixture, which provides a heat absorbing material that in its liquid state, is typically moulded or cast to suit any shape or form for use and baked for no more than 24h at about 40°C so that the binder composition dries slowly.

Some Examples of pcm/magnesia cement binder compositions, and the corresponding molar ratios for the magnesia, are given in Tables 1 to 3.

Table 1. where the Baumé of the Solution is 26°: ____________________________ sxample 1 sxampie 2 NsoMAo(RTM) Mgci (g) 500 500 Mater (g) 500 500 saymag MgO -comprising of: 400 250 Magnesium Oxide: 94 -94% (ut.ut) Calcium Oxide: 1.5 -4% 5A5F Micronal mPcM 600 600 snthalpy Measure (kJ/kg) 29.5 48.9 Furoclass Fire Rating c 0 Table 2. Where the Baumé of the Solution is 23°: ____________________________ Example 3 Example 4 NEDMAG(RTM) MgClo (g) 262 262 Water (g) 338 338 Baymag MgO -comprising of: 250 50 Magnesium Oxide: 94 -98% (wt.ut) Calcium Oxide: 1.5 -4% CIBA Encapulance mPCM 1000 1000 Enthalpy Measure (kJ/kg) 68.1 102.6 Euroclass Fire Rating E E/F Table 3. Molar ratios for MgO:MgC12:H20 and weight ratios for cement:pcm in

Examples 1-4

Baumé Example MgO MgC12 H20 Enthalpy Euroclass Cement:pcm 26° 1 4.0 1.00 17.3 29.5 C 2.3 26° 2 2.5 1.00 17.3 48.9 D 2.1 23° 3 4.8 1.00 20.6 68.1 E 0.85 23° 4 1.0 1.00 20.6 102.6 E/F 0.65 In Examples 1 and 2, the molar ratio of magnesium chloride: water is 1:17.3, Corresponding to a Baumé value of 26°, and in Examples 3 and 4, the molar ratio of magnesium chloride: water is 1:20.6, Corresponding to a Baumé value of 23°. This is lower than the Baumé value of 28° to 34° taught in In Examples 1 and 3 the molar ratio of magnesium Chloride: magnesium oxide is between about 1:4 and 1:5. The molar ratio of MgO:MgC12:H20 in the magnesia cement of the present invention thus varies in the ranges 4- 5:1:17.3-20.6. This is considerably different from the magnesia cements utilised in Examples 10 and 11 of W02009/059908 (a ratio of 5.3:1:12) and Examples 12 and 13 of W02009/059908 (a ratio of 8:1:16).

The molar ratio of the added magnesium oxide: magnesium chloride is generally in the range of about 4:1 to about 5:1, but much lower molar ratios (as low as about 1:1) are utilised when a larger quantity of phase change material is to be incorporated into the binder as in Examples 2 and 4. The greater the volume of phase change material that can be incorporated into the present invention, the higher the enthalpy measure and subsequently the greater the heat storage capacity of the material. In addition, where the Baumé of the solution is reduced to 23°, the volume of magnesium oxide in the binder is also reduced as a result (to keep the molar ratio of magnesium chloride: magnesium oxide in the same range) as in Example 4. Therefore a higher volume of phase change material can be incorporated into the mixture.

The increase in water content of the solution will evaporate during the curing stages of the binder/mixture.

Using a weight ratio of magnesia cement materials: pcm in the range of 1:2 to 1:3 gives a binder product having an enthalpy measure of about 50 kJ/kg.

The binder product of the present invention is thus rather superior to that disclosed in W02009/059908 in which the weight ratio of magnesia cement materials: pcm in the range of 1:0 to 1:2 and the enthalpy measures are in the range of 13 to 33 kJ/kg.

The microencapsulated phase change material alone is highly flammable, and in Examples 3 and 4 the Euroclass fire rating is low: casting the mixture into aluminium, copper or graphite encasements prior to baking protects the binder from fire and give the binder a practical format with high thermal conductivity benefits for a number of applications.

In a second embodiment of the present invention in which a high enthalpy is secondary to the density and strength requirements, and aggregate fillers such as, but not limited to, silica sand, stone dust, quartz, perlite, marble, ceramic powders, or graphite can be added to the binder with phase change material mixture. This gives the material additional strength and durability characteristics for other applications where aluminium, copper or graphite casing are not necessary or practical. Table 4 provides details of formulations containing quartz, and the corresponding molar ratios for the magnesia are given in Table 5.

Table 4. Where the Baumé of the Solution is 26° and incorporating Quartz into Binder mixture

Example 5 Example 6

NEDMAG(RTM) Mgc12 (g) 150 500 Water (g) 150 500 Baymag MgO -comprising of: 150 400 Magnesium Oxide: 94 -98% (dat) Calcium Oxide: 1.5 -4% CIBA Ericapulance mPcM 150 600 Quartz 150 100 Enthalpy Measure (kJ/kg) 48.8 47.0 Euroclass Fire Rating c c Table 5. Molar ratios for MgO:MgC12:H20 and weight ratios for oement:pom In

Examples 5 and 6

Baumé Example MgO MgC12 BO Bnthalpy Buroolass Cement:pom 26° 5 5.0 1.00 17.3 48.8 C 3.0 26° 6 4.0 1.00 17.3 47.0 C 2.3 The molar ratio of MgO:MgC12:B20 in the magnesia oement of this seoond embodiment thus varies in the ranges 4-5:1:17.3, oonsiderably different from the magnesia oements utilised in Examples 10 and 11 of w02009/059908 (a ratio of 5.3:1:12) and Examples 12 and 13 of w02009/059908 (a ratio of 8:1:16) Prior to the baking step, these formulations oan be oast to form wall and floor tiles, floor ooatings and soreeds, worktops, furniture, exterior oladding and siding panels, oonstruotion boards and building blooks and internal and external arohiteotural mouldings. Also organio fillers inoluding, but again not limited to, wood dust, flax sheaves, hemp and straw oan be added as fillers in the manufaoture of a oonstruotion board for interior/exterior walls and also oeilings.

In a third embodiment in whioh the enthalpy of the binder exoeeds 5OkJ/kg, the fire rating reduoes to Buroolasses B and F and is therefore limited in its use as a building material. In order to overoome this, intumesoent agent of the type disolosed in U.S. Patent Appi. Pub. No. 2003/02ll796Al is added, again with mixing, to the binder and phase ohange material mixture. Typioal intumesoents are latex aqueous dispersions. Preferred intumesoents inolude Thermasorb and A/D Firefilm III from Carboline, whioh are water-based intumesoents. Example 8 shows how the addition of Thermasorb alters the Buroolass Fire Rating for a magnesia oement oontaining Bnoapsulanoe from B (Example 7 in the absenoe of Thermasorb) to C. Table 6. where the Baumé of the Solution is 26° and inoorporating intumesoent into the Binder mixture of example 8 only.

Fxampie 7 Fxampie 8 NFOMAO(RTM) Mg012 (g) 300 300 Water (grams) 300 300 saymag MgO -comprising of: 250 250 Magnesium Oxide: 94 -98% (utut) Caicium Oxide: 1.5 -4% 015A sncapuiance mPCM 1000 1000 Intumescent -Carboline 0 200 Thermasorb (grams) Bnthaipy Measure (kJ/kg) 66.3 48.9 Furociass Fire Rating F C Table 7. Molar ratios for MgO:MgC12:H20 and weight ratios for oement:pom In

Examples 7 and 8

Baumé Example MgO MgCl H20 Enthalpy Euroolass Cement:pom 26° 7 4.20 1.00 17.3 66.3 B 0.85 26° 8 4.20 1.00 17.3 48.9 C 0.85 For high enthalpy binders with poor Furoolass Fire Ratings, the mixtures are oast into an enoasement that preferably oomprises aluminium or oopper or a oombination thereof prior to the baking step. These materials have good thermal oonduotivity (aluminium -237 (W/m k), oopper -401 (W/m k) as apposed to other enoasements made with plain steel, for an example, whioh has a thermal oonduotivity value of 45-65 (W/m k) . They therefore maximise the effioienoy of the phase ohange material.

The enoasements oan be formed into embodiments inoluding, but not limited to, oeiling tiles, ohilled oeiling systems, heating and oooling exohange units, wall panels, oomputer room floor tiles, raised aooess floor panels, ourtain walling seotions, suspended oeiling seotions, extrusions for lightweight oonorete floors, window and door frames, sleeving for heating and ventilation pipe work or duoting, and teleoommunioation and data rooms.

In a fourth embodiment, a binder formulation having very high enthalpy, for example over lOOkJ/kg, or over l5OkJ/kg, utilising a seoondary binder of the type disolosed in CR2344341 (PEA binder) is detailed in Examples 9 and 10.

Table 8. where a seoondary binder is utilised.

Fxample 9 Fxample 10 Fxample 11 N5OMAG(RTM) MgC1 (g) 50 44 0 Water (g) 50 56 100 saume of MgC12:H2O 26 23 -solution saymag MgO (grams) - comprising of: 50 44 -Magnesium!Cxide: 94 -98% (ut.ut) Calcium Celia: 1.5 -4% 015A socapulance M pom 150 250 (grams) PFA 5ioder (grams) 50 50 50 snthalpy Measure (kJ/kg) 144 101 155 Furoclass Fire Rating s/F s/F F Table 9. Molar ratios for MgO:MgC12:H20 and weight ratios for oement:pom In

Examples 9 and 10

Baumé Example MgO MgC12 BO Bnthalpy Buroclass Cement:pcm 26° 9 5.04 1.00 17.3 144 B/F 1.00 23° 10 5.04 1.00 20.4 101 B/F 0.96 This gives a binder having a Buroclass fire rating of B/F. This seoondary binder oomprises dry, inert powder suoh as fly ash, pulverised rook or recycled building waste, phosphogypsum whioh is a by produot of phosphorio aoid produotion for phosphate fertiliser, and an alkaline salt of any metal and so may also be an industrial waste or by-produot, for example, cellulose produotion. The dry, inert powder may be a major proportion by weight and may oomprise 65-65%, preferably 74 -76% by weight of the seoondary binder. The alkaline salt may oomprise 0.2 -1.0%, preferably 0.4 -0.6% by weight of the seoondary binder. By way of example and not restrioted to, a seoondary oompound oomprising fly-ash (75%), phosphogypsum (24.5%) and alkaline salt (0.5%) would be preferred for a variety of constructional materials. A suitable seoondary binder is available from AMPC International Technologies (Cyprus) Ltd and has the produot oode 1ST. It is a quick setting, fireproof, lightweight, high thermal resistanoe oompound.

In the formulation prooess where a magnesium oement binder and phase ohange material is used (Examples 9 and 10), the seoondary binder is added when both of the aforementioned oomponents have been mixed. It is reoommended that the mixture of magnesium oement binder, phase ohange material and seoondary binder is stirred vigorously for a further 10 -15 minutes at high speed after the seoondary binder has been added. This is to ensure that there is even dispersion of the secondary binder within the mixture. In this formulation, the weight: weight ratio of secondary binder to phase change material is 1:3.

The use of a secondary binder provides components that ran be used in cooling systems, both passive and mechanical. These include chilled beam systems, ceiling tiles and computer/raised access floor panels, wall panels for computer data and server rooms, isolated telecommunication rooms. The important aspect of using the secondary binder with the phase change material is that is has to be in an encasement which is made from either aluminium, copper, steel, rigid PVC, timber, plastics, glass, graphite, concrete, and cementitious or gypsum floor screeds.

In a fifth embodiment, inclusion of the secondary binder alone along with the phase change material and therefore excluding the magnesium cement binder yields higher enthalpy results of l5OkJ/kg and above (see Example 11 above) This is because the nature of the secondary binder allows for a higher volume of phase change material by weight to be added to a small volume by weight of the secondary binder. However the drawback of the secondary hinder when used in this formulation is that it has limited / non-existent fire resistant properties and therefore will only achieve Furoclass classification F. As such the formulation can only be used in embodiments that consist of an encasement of some description that meets the local or national minimum building regulation standard. An example of encasement materials include but not limited to aluminium, copper, steel, graphite, timber, rigid P.V.C.

Where the formulation does not include the magnesium cement binder, the secondary binder and water are mixed for 5 -10 minutes at high speed prior to the phase change material being added. After adding the phase change material the mixture is mixed for a further 10 -15 minutes.

In this formulation, the weight ratio of secondary binder to phase change material is 1:5. The average mean enthalpy of preparations of this type are far superior than any achieved using a Sorel cement formulation. However this needs to be encased in aluminium or copper to give fire resistance.

In these high enthalpy embodiments, an intumescent agent of the type described above may also be added.

Claims

Claims 1. A latent heat storage material having improved fire-retardant properties and including a binder and a phase change material, characterised by said binder including dry inert powder, phosphogypsum, and an alkaline salt of any metal.
2. The latent heat storage material of claim 1 wherein said dry inert powder comprises 65-85% by weight of said binder.
3. The latent heat storage material of claim 1 wherein said alkaline salt comprises 0.2 -1.0% by weight o said binder.
4. The latent heat storage material of claim 1 wherein said binder comprises 75% by weight of fly-ash, 24.5% by weight of phosphogypsum and 0.5% by weight of alkaline salt.
5. The latent heat storage material of any of the preceding claims additionally comprising a filler material.
6. The latent heat storage material of claim 5 wherein said filler is selected from the group consisting of: silica sand, stone dust, quartz, perlite, marble, ceramic powders, wood dust, flax sheaves, hemp, straw and graphite.
7. The latent heat storage material of claim 5 or 6 in which said material is cast to form wall tiles, floor tiles, floor coatings, floor screeds, worktops, furniture, exterior cladding and siding panels, construction boards and building blocks and internal and external archLtectural mouldings.
8. The latent heat storage material of any of the preceding claims additionally comprising an intumescent agent.
9. The latent heat storage material of claim 8 wherein said tntumescent agent is a latex aqueous dispersion.
10. The latent heat storage material of any of the preceding claims in which a weight ratio of said secondary binder to said phase change material is 1:3.
11. The latent heat storage material of any of the preceding claims wherein said material is cast into an encasement comprising a metal with high thermal conductivity.
12. The latent heat storage material of claim 11 wherein said metal is aluminium or copper.
13. The latent heat storage material of claims 11 or 12 wheretn said encasements form ceiling tiles, chilled ceiling systems, heating and cooling exchange units, waii paneis, computer room floor tiies, raised access floor panels, curtain walling sections, suspended ceiling sections, extrusions for lightweight concrete floors, window and door frames, sleeving for heating and ventilation pipe work or ducting, telecommunication and data rooms.
14. The latent heat storage material of any of the preceding claims having an enthalpy in the range of 40 to 50 kJ/Kg.
15. The latent heat storage material of any of claims 1 to 13 having an enthalpy more than 50 kJ/Kg.
16. The latent heat storage material of any of claims 1 to 13 having an enthalpy more than 100 kJ/Kg.
17. The latent heat storage material of any of claims 1 to 13 having an enthalpy more than 150 kJ/Kg.
18. The latent heat storage material of any of the preceding claims in which said phase change material is in a microencapsulated form.
19. A ceiling tile comprising the latent heat storage materials of any of the preceding claims.
20. A computer floor tile comprising the latent heat storage materials of any of the preceding claims.
21. A process for making a latent heat storage material having improved fire-retardant properties and including a phase change material and a hinder including dry inert powder, phosphogypsum, and an alkaline salt of any metal and comprising the steps: (a) mixing said hinder and water for 5 -10 minutes at high speed; Kb) adding phase change material and continuing to mix for a further -15 minutes; and (c) baking the mixture.
22. The process of claim 21 in which said step of adding said phase change material comprises mixing vigorously.
23. The process of claims 22 or 23 in which said baking step comprises baking for no more than 24h at about 40°C so that the composition dries slowly.
24. The process of any of claims 21 to 23 in which said dry inert powder comprises 65-85% by weight of said binder.
25. The process of any of claims 21 to 24 wherein said alkaline salt comprises 0.2 -1.0% by weight of said binder.
26. The process of any of claims 21 to 23 wherein said binder comprises 75% by weight of fly-ash, 24.5% by weight of phosphogypsum and 0.5% by weight of alkaline salt.
27. The process of any of claims 21 to 26 additionally comprising the step of adding a filler material.
28. The process of any of claim 27 wherein said filler is selected from the group consisting of: silica sand, stone dust, quartz, perlite, marble, ceramic powders, wood dust, flax sheaves, hemp, straw and graphite.
29. The process of any of claim 27 or 28 in which said material is cast to form wall tiles, floor tiles, floor coatings, floor screeds, worktops, furniture, exterior cladding and siding panels, construction hoards and building blocks and internal and external architectural mouldings.
30. The process of any of claims 21 to 29 additionally comprising the step of adding an intumescent agent.
31. The process of claim 30 wherein said intumescent agent is a latex aqueous dispersion.
32. The process of any of claims 21 to 30 additionally comprising the step of casting to form wall tiles, floor tiles, floor coatings, floor screeds, worktops, furniture, exterior cladding and siding panels, construction boards and building blocks and internal and external architectural mouldings.
33. The process of any of claims 21 to 30 additionally comprising the step of casting to form a ceiling tile.
34. The process of any of claims 21 to 30 additionally comprising the step of casting to form a computer floor tile.
35. The process of any of claims 21 to 34 in which said phase change material is in a microencapsulated form.Amendments to the claims have been filed as follows: 1. A latent heat storage material having improved fire-retardant properties and including a binder and a phase change material, characterised by said binder including dry inert powder, phosphogypsum, and an alkaline salt of any metal.2. The latent heat storage material of claim 1 wherein said dry inert powder comprises 65-85% by weight of said binder.3. The latent heat storage material of claim 1 wherein said alkaline salt comprises 0.2 -1.0% by weight of said binder.4. The latent heat storage material of claim 1 wherein said binder comprises 75% by weight of fly-ash, 24.5% by weight of phosphogypsum and 0.5% by weight of alkaline salt.5. The latent heat storage material of any of the preceding claims additionally comprising a filler material.6. The latent heat storage material of claim 5 wherein said filler is selected from the group consisting of: silica sand, stone dust, quartz, r perlite, marble, ceramic powders, wood dust, flax sheaves, hemp, straw and graphite.7. The latent heat storage material of claim 5 or 6 in which said material is cast to form wall tiles, floor tiles, floor coatings, floor screeds, worktops, furniture, exterior cladding and siding panels, construction boards and building blocks and internal and external architectural mouldings.8. The latent heat storage material of any of the preceding claims additionally comprising an intumescent agent.9. The latent heat storage material of claim 8 wherein said intumescent agent is a latex aqueous dispersion.10. The latent heat storage material of any of the preceding claims in which a weight ratio of said binder to said phase change material is 1:5.11. The latent heat storage material of any of the preceding claims wherein said material is cast into an encasement comprising a metal with high thermal conductivity.12. The latent heat storage material of claim 11 wherein said metal is aluminium or copper.13. The latent heat storage material of claims 11 or 12 wherein said encasements form ceiling tiles, chilled ceiling systems, heating and cooling exchange units, wall panels, computer room floor tiles, raised access floor panels, curtain waiiing sections, suspended ceiiing sections, extrusions for lightweight concrete floors, window and door frames, sleeving for heating and ventilation pipe work or ducting, telecommunication and data rooms.14. The latent heat storage material of any of claims 1 to 13 having an enthalpy more than 150 kJ/Kg.15. The latent heat storage material of any of the preceding claims in which said phase change material is in a microencapsulated form.16. A ceiling tile comprising the latent heat storage materials of any of the preceding claims.17. A computer floor tile comprising the latent heat storage materials of any of the preceding claims.18. A process for making a latent heat storage material having improved fire-retardant properties and including a phase change material and a hinder including dry inert powder, phosphogypsum, and an alkaline salt of any metal and comprising the steps: C (a) mixing said hinder and water for 5 -10 minutes at high speed; (b) adding phase change material and continuing to mix for a further 10 -15 minutes; and (c) baking the mixture. 19. The process of claim 18 in which said step of adding said phase change material comprises mixing vigorously. r20. The process of claims 18 or 19 in which said baking step comprises baking for no more than 24h at about 40°C so that the composition dries slowly.21. The process of any of claims 18 to 23 in which said dry inert powder comprises 65-85% by weight of said binder.22. The process of any of claims 18 to 21 wherein said alkaline salt comprises 0.2 -1.0% by weight of said binder.23. The process of any of claims 18 to 21 wherein said binder comprises 75% by weight of flyash, 24.5% by weight of phosphogypsum and 0.5% by weight of alkaline salt.24. The process of any of claims 18 to 23 additionally comprising the step of adding a filler material.25. The process of any of claim 24 wherein said filler is selected from the group consisting of: silica sand, stone dust, quartz, perlite, marble, ceramic powders, wood dust, flax sheaves, hemp, straw and graphite.26. The process of any of claim 24 or 25 in which said material is cast to form wall tiles, floor tiles, floor coatings, floor screeds, worktops, furniture, exterior oiadding and siding paneis, oonstruotion boards and buiiding biooks and internai and externai arohitecturai mouidings.27. The prooess of any of oiaims 18 to 26 additionaiiy comprising the step of adding an intumesoent agent.28. The prooess of oiaim 27 wherein said intumesoent agent is a iatex aqueous dispersion.29. The process of any of ciaims 18 to 27 additionaiiy comprising the step of casting to form waii tiies, fioor tiies, fioor coatings, fioor screeds, worktops, furniture, exterior cladding and siding panels, construction boards and building blocks and internal and external architectural mouldings.30. The process of any of claims 18 to 27 additionally comprising the step of casting to form a ceiling tile.31. The process of any of claims 18 to 27 additionally comprising the step of casting to form a computer floor tile.32. The process of any of claims 18 to 31 in which said phase change 0 material is in a microencapsulated form. r c'J r